installation recommendations forFLOATING DOCKS, RAFTS AND BOAT WELLS

CREATE BUILD-IT-YOURSELF FLOATING STRUCTURES WITH STYROFOAM™ BRAND BUOYANCY BILLETSThese instructions describe the materials needed and guidelines for building floating docks, rafts and boat wells/docks with STYROFOAM™ Brand Buoyancy Billets.

Extremely buoyant and durable, the billet material is composed of millions of tiny non-interconnecting air cells – each serving as an independent buoyancy chamber. These billets won’t lose their buoyancy, even if punctured. It takes only 1 cubic foot (0.03 cubic meter) of STYROFOAM™ Brand Buoyancy Billets to float 55 pounds (25 kilograms).

Lightweight, the billets are easy to install. And they stay on the job year after year under normal conditions. They resist the attack of destructive marine growths, are unaffected by salt or fresh water, won’t become waterlogged and won’t corrode.

®™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow

MATERIALS CHECKLISTUÊHandsawUÊFraming squareUÊHandheld drillUÊHammerUÊWrenchUÊCarriage bolts/washers/nuts (see Table 1)UÊTreated wood* (see Table 1) UÊNails (see Table 1)UÊScrap of 1/2" (13 mm) plywood

PLANS FOR A FLOATING DOCKThese instructions describe the materials needed and guidelines for building a 6' x 10' (1.8 m x 3 m) floating dock. Additional sections can be made to increase the length of the dock. The materials needed for one section are shown in Table 1. The plans for the floating dock are shown in Figure 1.

Part Name Size, inch (cm) Quantity Needed

Deck Braces 2 x 10 x 117 (5 x 25 x 297) 1

Deck Braces 2 x 10 x 33-3/4 (5 x 25 x 85.7) 2

Deck Sides 2 x 10 x 120 (5 x 25 x 305) 2

Deck Ends 2 x 10 x 72 (5 x 25 x 183) 2

Skirts 2 x 6 x 120 (5 x 15 x 305) 2

Skirts 2 x 6 x 72 (5 x 15 x 183) 2

Cross Ties 2 x 6 x 72 (5 x 15 x 183) 3

Decking 2 x 6 x 72 (5 x 15 x 183) 20

Skids 2 x 6 x 108 (5 x 15 x 274) 2

Corners 4 x 4 x 16-1/4 (10 x 10 x 41) 4

Galvanized Carriage Bolts with Nuts (or threaded rod cut to required length)

Diameter: 3/8 (0.95) Length: 16 (41)

6

Galvanized Carriage Bolts with Nuts (or threaded rod cut to required length)

Diameter: 3/8 (0.95) Length: 6 (15)

16

Galvanized Nails Length: 3-1/2 (9) 6 lbs (2.7 kg)

Galvanized Washers Diameter: 3/8 (0.95) 22

STYROFOAM™ Brand Buoyancy Billets

10 x 20 x 96 (25 x 51 x 244) 2

table 1: materials for dock

16" (41 cm) Carriage bolt – washer under nut

10' (3 m)

Corners

6' (1.8 m)

Deck braces

Decking

Counterbore1/2" (1.3 cm) for carriage bolts

STYROFOAM™ Brand Buoyancy Billets –combined 1220 lbs (553 kg) buoyancy

Sides and ends

Cross ties

Skirtsall around

6" (15 cm) Carriage bolts –washer under nut

figure 1: floating dock plan

®™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow

figure 2: bottom view of dock

figure 3: attaching billets to bottom of dock

figure 4: attaching decking to top of raft or dock

CONSTRUCTION STEPS1. Following the illustrations, create the

framework shown in Figure 2. With the frame structure upside down, nail on the three cross ties and the four skirt boards.

2. Consulting Figure 3, lay the STYROFOAM™ Brand Buoyancy Billets across the cross ties. Place skids on the foam as shown. To connect the foam, drill six holes through the skids, foam, and the cross ties. Insert the long bolts and reach under the cross ties to apply washers and nuts.

3. Turn the structure over and tighten the nuts to a snug fit.

4. Install lengthwise brace. Then install cross bracing.

5. Nail on deck boards using a piece of 1/2" (13 mm) plywood to space boards 1/2" apart (Figure 4).

REPLACING EXISTING DRUMSEasily replace drums on a boat well/wharf with buoyancy billets while the floating structure is still in the water. The rocking that is usually experienced in drum-floated structures is greatly reduced by using STYROFOAM™ Brand Buoyancy Billets.

1. Replace small sections one at a time. Sink and remove only two side-by-side drums at a time.

2. Build a crib from lumber – 2" x 8" (5 x 20 cm) boards are suggested. Fasten the crib to the STYROFOAM™ Brand Buoyancy Billet. Cross members should be longer than the wharf is wide.

3. Tilt crib and push under wharf using the 2" x 8" boards as handles.

4. Center under the wharf. Secure with 16 pennyweight (16d) nails. Saw off protruding 2" x 8" handles.

Product Cubic Feet (Cubic Meters)

Approximate Weight, lbs (kg)

Approximate Buoyancy, lbs (kg)

Billet Size, inch (cm)

7 x 20 x 96 (18 x 51 x 244) 7.7 (0.22) 14 (6.4) 425 (192.8)

10 x 20 x 96 (25 x 51 x 244) 11.1 (0.31) 20 (9.1) 610 (276.7)

7 x 20 x 108(1) 8.6 (0.24) 16 (7.3) 480 (217.7)

10 x 20 x 108(1) 12.5 (0.35) 23 (10.4) 690 (313.0)

10 x 24 x 96(1) 13.3 (0.38) 24 (10.9) 730 (331.1)

Drum Size

55-gallon (208-liter), 18-gauge 7.8 (0.22) 48.5 (22.0) 440 (199.6)

table 2: comparative size and buoyancy data

DRUM REPLACEMENT STEPS

Plus, there are no hollow drumming noises to listen to at night.

One 10" x 20" x 96" (25 x 51 x 244 cm) STYROFOAM™ Brand Buoyancy Billet has an average buoyancy that is approximately 150 percent greater than a 55-gallon (208-liter) drum (Table 2).

(1) Available in the U.S. only

®™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow

figure 6: bottom view of raft

figure 7: attaching billets to bottom of raft

Part Name Size, inch (cm) Quantity Needed

Sides 2 x 10 x 144 (5 x 25 x 366) 2

Ends 2 x 10 x 93 (5 x 25 x 236) 2

Deck Braces 2 x 10 x 141 (5 x 25 x 358) 2

Deck Braces 2 x 10 x 330 (5 x 25 x 76) 3

Skirts 2 x 6 x 144 (5 x 15 x 366) 2

Skirts 2 x 6 x 93 (5 x 15 x 236) 2

Cross Ties 2 x 6 x 96 (5 x 15 x 244) 4

Decking 2 x 6 x 96 (5 x 15 x 244) 24

Skids 2 x 6 x 134 (5 x 15 x 340) 3

Corners 4 x 4 x 16-1/4 (10 x 10 x 41) 4

Galvanized Carriage Bolts with Nuts (or threaded rod cut to required length)

Diameter: 3/8 (0.95) Length: 16 (41)

12

Galvanized Carriage Bolts with Nuts (or threaded rod cut to required length)

Diameter: 3/8 (0.95) Length: 6 (15)

16

Galvanized Nails Length: 3-1/2 (9) 6 lbs (2.7 kg)

Galvanized Washers Diameter: 3/8 (0.95) 28

STYROFOAM™ Brand Buoyancy Billets 10 x 20 x 96 (25 x 51 x 244) 3

table 3: materials for swimming raft

figure 5: swimming raft plan

DeckingCorners

Deck braces

Sides and ends

Skirts all around

Cross ties

6" (15 cm) Carriage bolt – washer under nut

12' (3.7 m)8' (2.4 m)

STYROFOAM™ Brand Buoyancy Billets –combined 1830 lbs (830 kg) buoyancy

Skids –counterbore1/2" (1.3 cm)for carriage bolts

16" (41 cm) Carriage bolt – washer under nut

PLANS FOR A SWIMMING RAFTThese instructions describe the materials needed and guidelines for building an 8' x 12' (2.4 m x 3.7 m) swimming raft. The materials needed are shown in Table 3. The plans for the raft are shown in Figure 5.

CONSTRUCTION STEPS1. Following the illustrations, create the

framework shown in Figure 6. With the frame structure upside down, nail on the four cross ties and the four skirt boards.

2. Cut the three STYROFOAM™ Brand Buoyancy Billets in half for the six shorter pieces shown in Figure 7.

3. Consulting Figure 7, lay the sections of the STYROFOAM™ Brand Buoyancy Billets across the cross ties. Place skids on the foam as shown. To connect the foam, drill six holes through the skids, foam and the cross ties. Insert the long bolts and reach under the cross ties to apply washers and nuts.

4. Turn the structure over and tighten the nuts to a snug fit.

5. Install lengthwise bracing first, then install cross bracing.

6. Consulting Figure 4, nail on deck boards using a piece of 1/2" (13 mm) plywood to space boards 1/2" apart.

®™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow

Printed in U.S.A. Form No. 179-04291X-0511P&M 178-00548X-0511P&M

McKAY209257

NOTICE: No freedom from any patent owned by Dow or others is to be inferred. Because use conditions and applicable laws may differ from one location to another and may change with time, Customer is responsible for determining whether products and the information in this document are appropriate for Customer’s use and for ensuring that Customer’s workplace and disposal practices are in compliance with applicable laws and other government enactments. The product shown in this literature may not be available for sale and/or available in all geographies where Dow is represented. The claims made may not have been approved for use in all countries or regions. Dow assumes no obligation or liability for the information in this document. References to “Dow” or the “Company” mean the Dow legal entity selling the products to Customer unless otherwise expressly noted. NO EXPRESS WARRANTIES ARE GIVEN EXCEPT FOR ANY APPLICABLE WRITTEN WARRANTIES SPECIFICALLY PROVIDED BY DOW. ALL IMPLIED WARRANTIES INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY EXCLUDED.

THE DOW CHEMICAL COMPANY . Dow Building Solutions . 200 Larkin . Midland, MI 48674DOW CHEMICAL CANADA ULC . Dow Building Solutions . Suite 2100 . 450 – 1st St., SW . Calgary, AB T2P 5H1

For Technical Information: 1-866-583-BLUE (2583) (English) . 1-800-363-6210 (French) For Sales Information: 1-800-232-2436 (English) . 1-800-565-1255 (French)

www.dowbuildingsolutions.com

HOW TO SECURE FLOATING DOCKS AND RAFTS

Boltthroughpipe intosea wall

Guide platebolted tofloat (loosefit on pipe)

Standoffnipple

Guide pipe

TOP VIEW

SIDE VIEW

DOCK TO SEAWALL FOR TIDAL VARIATION Loose-fitting steel rod

Galvanized eye bolts

Washer andcotter pin

Float number 1 Float number 2

Galvanized washersat both endsof eye bolts

TOP VIEW

SIDE VIEW

DOCK TO DOCK

Use weighted sentinelif necessary for added holding

Chain bridleSingle chain

FLOAT

SIDE VIEW

RAFT TO BOTTOM

Float

Leav

e Cl

eara

nce

PilingPipe nipples (free fit on chain)

BoltEye bolt washersat both ends

Lt.anchor chain

Bolt forretaining pipenipples

TOP VIEW

DOCK TO PILING FOR TIDAL VARIATION

Cable stays topipe stakes

Welded pipe frame

Pivot bracket

Pipe frameCable

Float

1/2" Section8" Pipe

Pipe driven deep

SIDE VIEW

TOP VIEW

DOCK TO SHORELINE

PRECAUTIONS

STYROFOAM™ Brand Buoyancy Billets are sold for use in marine applications only. Billets are combustible. Protect from high heat sources. Care should be taken not to expose material to open flame or other ignition sources. For more information, consult MSDS, call Dow at 1-866-583-BLUE (2583) or contact your local building inspector. In an emergency, call 1-989-636-4400 in the U.S. or 1-519-339-3711 in Canada.

The foam is subject to attack by some chemicals, including concentrated quantities of gasoline and oil. If this, or pollution by industrial waste is suspected, reaction of the foam should be checked prior to construction. In case of extreme pollution, additional protection – such as solvent-free epoxy coatings – may be required. Compatibility of the coating to the billet should be checked prior to applying the coating.

Skirt boards will protect foam from mechanical damage and degradation from ultraviolet light.